A Study on Welding of Thin Sheet of Ti6-Al-4V Alloy Using Fiber Laser and Its Characterization

In the present research work, an attempt has been made to study and investigate the weldability of 1.2-mm-thick Ti6-Al-4V alloy sheet using CW (continuous wave) fiber laser. The influences of the variable process parameters such as laser power, weld scanning speed and laser beam diameter on the microstructure, heat-affected zone (HAZ) and mechanical properties of the final butt-welded joints of Ti6-Al-4V sheets have been investigated. All the experiments were performed by using a CW fiber laser having a laser power capacity of 400 W. At different parameter setting conditions such as laser power varying from 200 to 350 W, weld scanning speed from 120 to 200 mm/min and laser beam diameter (0.4 mm) were considered for the experimentation. Based on the experiments weld quality was investigated and characterized in terms of the surface microstructure, micro-hardness, and tensile strength of the welded samples. Morphological studies at different processing conditions were carried out to study their effects on the HAZ (Heat-affected zone) and weld bead geometry. Microscopic images of welded samples clearly show a decrease in weld width of the welded sample with an increase in weld scanning speed and with increasing laser power increase in width was observed. At a scanning speed of 120 mm/min with varying power from 200 to 350 W the size of heat-affected zone (HAZ) are 3.55, 3.70, 3.84, 4.8 mm, and the corresponding size of fusion zones is 1.751 mm, 1.83 mm, 1.921 mm, 2.032 mm, respectively. The trend in micro-hardness variation was observed and it depends on grain size in laser welding. At 350 W laser power with varying speed from 120 to 300 mm/min, the micro-hardness values of the welded sample were found as 387.1, 395, and 403 HV. The tensile strength of the original sample was found to be 940 N/mm². The testing results of the welded sample have a maximum failure strength of 507 N/mm² at 350 W and 200 mm/min scanning speed. FESEM images of the welded sample at different processing conditions were used for the study of microstructural changes in the welded zone and the presence of defects at the micro level.